Patent Application
20050042072
The invention relates to a document processing system utilizing a transport system for passing sheet stacks between processing modules to provide optionally modular post-printer document processing.
In the sheet finishing industry, sheet stacks are transferred between processing equipment as various steps are performed on the stacks of sheets. This transfer is typically classified as “in-line” or “off-line,” and sometimes “near-line.”
“In-line” refers to two pieces of processing equipment having their sheet paths joined together such that individual sheets are passed from one system to the other sequentially and processed as such. While there are many examples of such “in-line” processing, one such prominent example is designed following the Xerox DFA (Digital Finishing Architecture) Standard. The DFA protocol spells out mechanical and software specifications for attaching finishing machinery to DFA compatible Xerox sheet printers. Many vendors make secondary equipment to create systems using this standard, including Standard Finishing, C.P. Bourg, Duplo, and others.
“In-line” systems are advantageous in that they require minimal operator interaction, and therefore, have lower overhead and least opportunity for operator error. The entire system is locked in a one-to-one speed relationship, however, limiting the performance of the entire system to that of the slowest component. Accordingly, a major disadvantage of the “in-line” system is the lack of a buffer to allow for continued processing by some portions of the system if other portions of the system temporarily cease operations. Another disadvantage is reduced versatility from two types of processing modules that are complexly coupled, inhibiting their separate use for other functions.
“Off-line” refers to sheets being transferred in some non-automatic fashion, usually in stacks of sheets. Examples include simple carts to and from which sheet stacks are manually transferred by an operator. “Off-line” systems have the advantage of being able to match a slower module to a faster device, optimizing overall performance. It is commonly accepted that a ratio of 2:1 or greater may be matched with such in-line processing. Additionally, the components of such “off-line” processing are not tightly coupled, allowing for more versatile use of each module. “Off-line” processing, however, necessarily requires greater operator interaction than “in-line” processing, increasing labor costs as well as the opportunity for operator error in the form of both mechanical damaged sheet stacks or movement of the stacks out of sequence, when sequence is important.
“Near-line” refers to a special case of “off-line” processing where the carts are more elaborate and custommated to automatically receive and discharge sheet stacks. The stacks may be electronically tracked to ensure sequence of processing, as disclosed in U.S. Pat. No. 6,192,295 B1 to Gunther. One example of this type of “near-line” processing is marketed by GTI. In the GTI cart system, stacks are laid on a cart and the cart is manually rolled to a feeder. The GTI cart is designed to custom mate to the GTI stacker and GTI feeder. Although operator error is less than the opportunity with true “off-line” the chance is not eliminated. The GTI cart has a clamping system that secures the stacks from movement, however, the system requires considerable operator effort to operate.
In accordance with the invention, there is provided a document handling system which utilizes one or more of an elevator transfer station, modular transfer station, transportation cart, storage station, and/or modular processing station to provide in-line document processing in a modular environment while allowing the use of one or more modular processing stations in an off-line manner without disconnection of the module from other modules that form part of the sheet handling system. Each of the transfer station, cart, and storage station includes a plurality of elongated support surfaces or fingers to create a sheet support surface, slotted platform or deck such that the alternating fingers and slots of the transfer station or cart storage station receive the alternating slots and fingers of the cart to transfer stacks of sheets supported on the upper surface to and from the cart and transfer station or storage station. Stacks of sheets may likewise be transported between adjacent processing modules by similarly intermeshed transfer stations or intermediate belts, rollers, or the like.
The transfer station includes a platform comprising a series of driven surfaces in the form of, for example, driven rollers or flat rotary belts, which are spaced to engage with a number of different structures. The transfer station may be a separate station or the transfer station components may be incorporated into a modular processing station. For ease of understanding, this application will refer to belts. It will be appreciated, however, that alternate designs, such as those utilizing a plurality of in-line driven rollers, are likewise form appropriate driven plurality of elongated support surfaces, and are to be considered to fall within the purview of the term “belt” as utilized herein. The spaced belts can intermesh with the slotted surface of a stacker, feeder, or other elevator mechanism such that the stack processing module can deposit or remove sheet stacks from the transfer station. Additionally, the spaced belts of the transfer station platform may intermesh with the slotted deck of the cart, such that the sheet stacks can be moved from one transfer station to another using the cart, without connecting the two transfer stations physically. Finally, the spaced flat belts of the transfer station platform can intermesh with the spaced flat belts of another transfer station or an intermediate station. Under these circumstances, the belts of the second transfer station are spaced at one-half pitch off that of its mate. In this way, transfer stations can be connected to form a conveyor between processing modules to transfer sheets or stacks of sheets, eliminating the need for manual intervention to move sheets or sheet stacks between processing modules during processing. The transfer station may be provided with an elevator mechanism that moves a stack of sheets supported thereon in a vertical elevation to provide the stack for further transfer or for further processing operation. It is further envisioned that preexisting processing stations may be retrofit with such transfer or elevator transfer stations to allow their integration into the document handling system.
The moveable cart would likewise have a slotted deck that could intermesh between the individual belts of the transfer station to form a joint sheet support surface. Preferably, the cart may be manually, electrically, hydraulically, or otherwise powered, and includes a mechanism whereby the cart deck can be raised or lowered by cam, lever, electrical power, hydraulics or other mechanism such that the cart may deposit a stack of sheets on the transfer station platform or raise a stack of sheets from the transfer station platform to remove the stack from the transfer station. Preferably, the cart includes a quick clamp release system to secure the sheet stack for transport. Additionally, the cart is preferably symmetrical such that a stack may be picked up or deposited from either side of the cart to readily provide phasing of the edges of the stack. The transfer station or elevator transfer station, as well as the processing modules themselves may provide for alternate movement of the support surfaces into or out of the sheet handling system to facilitate access by the cart. For example, the support surface or deck may move in a substantially perpendicular direction from the system to allow intermediate access to a stack of sheets. In this way, the cart may readily be utilized to access and remove a stack from the deck. The deck may then be retracted back into the system.
Finally, the storage station includes a slotted stationary platform where the slots are spaced to receive and intermesh with the slotted deck of the cart. In this way, the cart may be used to deposit the sheet stack on the storage station when the stack is not transferred directly to the elevator transfer station. The storage station may include upright stacking guides which may be adjustable or permanently spaced or installed. The stacking guide may also be removable for storage and to provide a tidy appearance. As with the elevator transfer station, the cart may be used to place a sheet stack on the storage station and the cart then lowered, leaving the stack on the storage station. Similarly, an empty cart may be intermeshed with the slotted platform of the storage station and the cart slotted deck raised to lift the sheet stack from the storage station for removal to an elevator transfer station.
While the cart has been described as including a movable deck, the storage station-and elevator transfer station may alternately include movable platforms for raising or lowering a sheet stack onto the cart having a stationary deck, or some combination of such arrangements.
The aforementioned document transport system facilitates an improved and novel document processing system. In particular, a modular transfer station mates with both processing module elevators and other transfer stations to allow a new version of “in-line” processing in which sheet stacks or individual sheets are passed automatically between processing modules with a relatively large buffer. The buffer allows large and numerous stacks to be placed between the modules allowing for considerable pauses in one module without a concurrent pause in the other modules in the inline process, and allows considerable mismatches in processing speeds between machines without forcing human intervention or modification of the modules to synchronize their processing speeds. Further, this movement between modules during in-line processing can take place without intervention by an operator and the incumbent risk of error.
Additionally, the cart that mates with the transfer station can be docked in one of two directions with the transfer station, allowing the operator to choose to reverse the processing orientation of the stack desired. The cart also includes a quick clamping system which allows the stack to be quickly secured without extended operator involvement.
Further, the same transfer station can be utilized for both a buffered version of in-line processing, and with the cart, off-line and near-line processing that requires little operator involvement.
In addition to the benefits provided by the document transport system in allowing the in-line processing system described herein, there are other salient features of the invention. For example, one or more modules that form the modular in-line processing system may be used in an off-line manner as well without disconnecting the relevant module(s) from the in-line system, or can be utilized as free standing, independent processing modules.
These and other advantages of the invention, as well as additional inventive features, will be apparent from the description of the invention provided herein.
FIGS. 4A-F are bottom perspective or plan views of various wheel configurations for the movable cart.
FIGS. 5C-I are fragmentary perspective views of various handle operation mechanisms, including buttons, levers, and cam locks.
FIGS. 6A-C are cross-sectional views of embodiments of locking arm uprights.
FIGS. 7A-D are fragmentary perspective views of various locking bar operation mechanisms, including buttons and levers.
FIGS. 15A-C are views of an alternate embodiment of a storage station.
FIGS. 16A-C are views of a second alternate embodiment of a storage station.
FIGS. 17A-C are views of a third alternate embodiment of a storage station.
FIGS. 18A-C are views of a fourth alternate embodiment of a storage station.
FIGS. 19A-C are views of a fifth alternate embodiment of a storage station.
FIGS. 20A-C are views of a sixth alternate embodiment of a storage station.
FIGS. 21A-D are views of a seventh alternate embodiment of a storage station.
FIGS. 22A-D are views of an eighth alternate embodiment of a storage station.
FIGS. 23A-D are views of a ninth alternate embodiment of a storage station.
FIGS. 25A-B are views of an eleventh alternate embodiment of a storage station.
FIGS. 26A-B are view of an alternate embodiment of a platform and deck finger design.
FIGS. 27A-C are views of a second alternate embodiment of a platform and deck finger design.
FIGS. 28A-B are views of a third alternate embodiment of a platform and deck finger design.
Turning now to the drawings, there are shown in
Turning to
In accordance with another feature of the invention, there is provided a moveable transportation cart 42 that includes a slotted deck 44. The cart 42 may operate electrically, hydraulically, manually, or by any other appropriate method. As with the transfer station platform 34, the slotted deck 44 of the cart 42 includes spaced deck fingers 46 having open deck slots 48 disposed therebetween. Significantly, the deck fingers 46 and slots 48 as well as the platform fingers 38 and slots 40 are spaced such that they may intermesh, as shown in
In order to facilitate movement of the sheet stack between the slotted deck 44 of the moveable cart 42 and the platform 44 of the transfer station 32, at least one or the other of the slotted deck 44 or the platform 34 is vertically moveable relative to the other. In the currently preferred embodiment, the slotted deck 44 is vertically moveable relative to the platform 34. In this way, the deck and platform fingers 46, 38 may be intermeshed and the slotted deck 44 either advance upward relative to the platform 34 to remove the sheet stack from the platform 34 or downward relative to the platform 34 to place a sheet stack on the platform 34. It will be appreciated, that this same function could be performed by movement of the platform 34 itself up or down vertically relative to the slotted deck 44.
In the currently preferred embodiment, when the slotted deck 44 is moved upward or downward vertically relative to the platform 34 and the cart body 50 itself Alternatively, the entire cart body 50 and the slotted deck 44 may be moved vertically upward or downward relative to both the platform 34 and the ground. This vertical movement may be accomplished by way of a cam arrangement, a lever, a gearing arrangement, electrical power, hydraulics, or other method to deposit or remove a stack from the belt system by any appropriate mechanism.
A number of cart docking arrangements may be provided to facilitate movement of the cart into position and to facilitate the intermeshing of the deck fingers 46 and the platform fingers 38. A few such possibilities are illustrated in
In order to facilitate movement of the cart 42, the cart includes one or more wheels, rollers, casters, or the like 52 which extend from the cart 42 to contact the ground. As shown in
Another cart docking arrangement is disclosed in
Yet another cart docking arrangement is illustrated in
In order to allow free movement of the cart 42 relative to the ramp arrangement 70, the ramp 70 includes a pair of rollers 77 disposed along either side of the central channel 72 as the ramp angles upward, and the upper surface of the ramp 70 includes a plurality of ball transfers 79 which allow the cart to move into axis relative to the transfer station 32.
Thus, it will be appreciated that the cart may have any number of potential configurations of wheels, rollers, casters, or the like. By way of example only, various potential wheel configurations are illustrated in
In order to facilitate easy movement of the cart 42 by an operator, cart 42 includes a handle 80 pivotably mounted to the cart body 50. The handle 80 is preferably of an inverted U-shape and may be locked in a vertical position or unlocked and swiveled to either side so that the cart 42 may be moved from either side. Unlocking of the handle would likewise release the brake on the wheels 52 to allow the cart to move forward or backward. The handle release mechanism may be in the form of cross bar 83 as shown in
The handle 80 may be formed by any appropriate means, and may include multiple components fabricated by different methods. For example, it may include extruded, cast, or molded portions and may be fabricated from plastic or metal, such as aluminum, for example, or any other appropriate material.
As may be seen in
In order to stabilize the sheet stacks on the upper slotted deck 44 of the movable cart 42, the cart 42 is provided with a locking arm arrangement 100. As shown in
As with the handle 80, the locking arm arrangement 100 may include any number of locking arrangements. In the currently preferred embodiment, the locking arm 104 includes a centrally elongated opening 110 which may be utilized as a handle for moving the locking arm 104 upward and downward along the uprights 102. The locking mechanism for the locking arm 104 may include arrangements such as a depressible button 112, 114 disposed along either the upper or lower surface of the handle portion 110 as illustrated in
The locking arm 104 may be constructed of any appropriate materials and by any appropriate method. For example, as shown in
In accordance with another important aspect of the invention, there is provided a storage station 130, as is shown, for example, in
As shown in
In order to provide added support to a sheet stack supported on the slotted platform 142 of the storage station 130, a back stop stacking guide arrangement 148 may be provided such as is shown in
As with the transfer station 32 and movable cart 42, the storage station 130 and related components may be of any appropriate design and material, and constructed according to any appropriate method. For example, those storage stations designs are illustrated in
The platform fingers 144 may be of an appropriate design and formed by any appropriate method. For example, the platform fingers 144 may be stainless rods, as shown in
Initially, a print job or other process at document source 2941 produces one or more documents for processing. A document will generally comprise a plurality of sheets, but may in unusual cases have only a single sheet. The document source 2901 may interface to a document supplementation device such as tab cutter 2903. In the illustrated example, the tab cutter 2901 provides and inserts index tabs or other dividers into documents produced by document source 2901, either during or after document production. A plurality of such documents is then flush or offset stacked to provide a single stack or succession of stacks, each including a plurality of documents. The sheet stacks formed by this process, preferably including tabs where appropriate, are conveyed to the first process module 2905, illustrated as a punch 2905, via the buffer transport segment 2939.
The buffer transport segment 2939 is usable either to convey documents to the first process module 2903 for processing, or to divert incoming documents to a temporary storage space, or buffer. The primary reason for sometimes buffering the document stream in this manner is to facilitate in-line processing between modules with different processing or production rates. For example, in the illustrated scenario, the printer 2941 may produce documents at a faster rate than the punch 2903 can process such documents. In this case, the buffer would absorb the difference in capacity. In this manner, for example, if the printer 2941 produced documents twice as fast as the punch 2905 could process them, the buffer would absorb approximately half the documents produced while documents continued to be produced.
After document production at the source 2941 ends, the buffer may be gradually emptied as the rest of the processing system 2901 continues to run. It will be understood that the maximum time during which such a mismatch can be alleviated by buffering is tied both to the degree of mismatch and the document capacity of the buffer system. It is also within the invention to provide a number of buffers, such as a primary buffer and one or more overflow buffers for excessive or unexpected mismatches or surges in document production. Note that the buffer between a slower supplying module and a faster consuming module will generally not be used, except to facilitate intervening offline processing. That is, the rate mismatch must be buffered only when the faster module precedes the slower. Although only a single buffer/transport unit 2939 is visible in the illustrated example, such a transport and buffer system will preferably be provided at the junction of any two processing modules, unless the modules incorporate a mechanism for transport to the next module, and, in the case of rate mismatch, for buffering excess incoming documents.
Once the document processing system 2901 has finished processing one or more documents, the documents are output to a user accessible location such as to a cart 2933 as described above or otherwise. In the illustrated example, the finished documents will have been punched, bound (with closed cover), and stacked.
Note that one or more modules in the document processing system 2901 are preferably usable in an offline manner without disconnection from the system 2901. Such off-line use could occur during in-line processing by buffering in-line documents during the offline processing. For example, in the illustrated example, the punch module 2905 may also be used in an off-line mode by a user, via an access on the side of the module 2905. Alternatively, an offline stack of documents may be fed to the input belt by a cart or other appropriate method. Thus, the user may initiate an offline use of the punch 2905 via a user interface thereon. In response to user initiation, the punch 2905 preferably completes work on the current document being processed and then begins to buffer all incoming documents for a brief period while the user completes an offline use, such as by inserting a document or documents to be punched and then retrieving the punched materials. When the user has completed the offline use, the punch 2905 preferably begins again to process documents in an inline fashion, either from a buffer or directly from the preceding module.
Conveniently, all or a lesser number of the processing modules may be utilized in an in-line processing job. In this regard, if a particular processing module is not to be utilized, the individual lifts, sets, or stacks may proceed through the module along the standard processing line with the relevant function (e.g. the punch) disengaged. Alternatively, a bypass path may be provided through the module.
The common elements tying major processing functions together are one or more transfer stations 3003. Documents to be processed are supplied initially via a transfer station or otherwise, generally in a stacked form, from one or more stackers 3005, 3007 and associated interface(s) 3011 where necessary. At that point, the stacked documents are supplied, preferably via a conveyor input as described more extensively above, to a feeder to be provided to the subsequent processing modules. From the feeder, the documents enter a first processing module such as a punch module 3015 for punching a series of holes through an edge of each document to facilitate later binding. 100911 Note that the punch module 3015 is shown as receiving one or more die sets 3017, which are used to define the precise manner in which the holes are made in the edge of each document. Further note that the punch module 3015 may also receive cover material from a cover feeder 3019 when desired. These covers are preferably associated with each document prior to actual punching so that the holes punched in the cover match to the holes punched in the associated document.
If further processing, such as binding, is to occur, then the punched document stacks, including punched covers where appropriate, are fed to an accumulator and/or other interface 3021 to a binding module 3023. The interface 3021 between the punch module 3015 and binding module 3023 may be either a custom interface such as when the modules are designed to cooperate, or alternatively by way of a transfer station. The binding module 3023 applies a binding to the punched documents received from the punch module 3015. Such bindings may be comb bindings, wire spiral bindings, polymeric nail-type bindings, or any other type of binding usable to secure punched pages together via cooperating holes. The binding module 3023 optionally receives and uses one or more crimp sets 3025 to define the manner in which a crimped binding is applied.
From the binding module 3023, the bound documents are optionally fed to a cover closer 3027 via a custom interface or transfer station. At this point, the finished documents are passed in a stacked manner to a transfer station, preferably via a book stacker 3029. Note that the finished documents may also be provided to a shingle conveyor 3031 from the cover closer 3027. Also, if binding is not desired, the punched documents may be passed to a stacker 3035 for retrieval from the processing system. At any stage, a user may manually retrieve or place documents as indicated by “manual in/out” component 3033. The user may optionally use a cart 3037, such as described above in detail with respect to
A flow chart of the actions and motor run sequences for entry and exit of document stacks from a processing system such as described above is shown in
At step 3109, a run command is issued to commence processing of the stack. The run command may be either automatically issued when the stack is properly positioned after step 3107, or may be manually issued by a user such as through making a selection from a graphical user interface. At step 3111, pursuant to the run command, a lift motor is run at high speed to lift the stack into position for further processing. Subsequently, the vertical position of the stack is checked at step 3113. If the stack is not yet at full height, the process reverts to step 3111, running the lift motor at high speed. Otherwise, at step 3115, the lift motor is slowed to low speed, the main motor is run to process the documents, and the stacker motor is run at low speed to output the processed documents.
From step 3115, the process continues to step 3117, where the document processing is periodically monitored for the occurrence of a sheet jam. If no sheet jam is found to have occurred, the process checks the status of the stack at step 3119 to determine whether the last needed lift has been performed. If it has not, then the process returns to step 3115 and the steps that logically follow. Otherwise, if the last lift has been performed, or if a sheet jam was detected at step 3117, the process moves to step 3121, causing the lift motor to reverse and return the remainder of the stack to the bottom position, causing the main motor to be stopped, and causing the stacker motor to run at high speed, clearing any free papers from the processing apparatus.
At step 3123, the status of the lift is checked, and if the stack is not yet at the bottom position, then the process returns to steps 3121. Otherwise, the process moves to step 3125, whereat the stacker motor is stopped and an access door to the stacker is opened. Once the stacker access door is opened, an output belt motor is run at step 3127 to bring the stack into a position from which a user can access the stack or from which the stack can be moved into a position that is user accessible. As discussed above, there may also be lateral movement of the lift surface, or other document-supporting surface, to facilitate loading and unloading of the stack. The status of the stack is checked at step 3129 to determine whether the stack has exited the process, such as by checking whether any part of the stack has not yet passed the stacker door. If the stack has not yet exited, the process returns to step 3127 where the output belt motor continues to run. Otherwise, at step 3131, the stack motor raises a stack platform on which the stack was most recently sitting back to a top position, ready for processing of another stack.
The logical organization of an exemplary user interface usable to implement an embodiment of the invention is shown schematically in
Adjustments that may be made preferably include adjustments for sheet width, length, tab adjust, throughput speed, lift size, book size, and/or final die set adjust as shown in adjustments section 3211. As indicated by die set section 3213, the user may set the process so that the necessary die set may be automatically determined and/or adjusted. Note that the interface to the process also includes a non-user interface 3215 for automatically receiving information from sensors, barcodes, and/or other sources and for causing one or more automatic actions in response thereto. The sensors and other information sources illustrated include the following: a sensor that detects a top sheet in a stack, a cart tag that may be automatically recognized, information received over a USB port, a bar code that can be read to determine a desired process etc., information received from a laptop or other computer, information received from a printer, information received by download such as over the Internet, a remote information source, etc. Note that any of the above can supply document content or processing instructions.
All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
It will be appreciated that a novel and useful document processing system has been disclosed herein by way of examples, and that it is the claims, rather than these examples that define the scope of the invention. In particular, preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US02/39834 | 12/13/2002 | WO |
